Haynes Volvo 340 & 360 Series Owners Workshop Manual 1850105146, 9781850105145

Citation preview

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Owners Workshop Manual

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Volvo 300 Series Owners

Workshop Manual Colin Brown Models covered All Volvo 340, 343 & 345 models; 1397 cc & 1721 All Volvo 360 models; 1986 cc

cc

Does not cover LPG conversion

(715-3R3)

ascot KLMNO PC

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes Publications, Inc 861 Lawrence Drive Newbury Park California 91320 USA

Acknowledgements Thanks are due to the Champion Sparking Plug Company who supplied the illustrations showing the spark plug conditions. Certain other illustrations are the copyright of AB Volvo, and are used with their permission. Duckhams Oils provided lubrication data. The cars used for workshop and photographic purposes were kindly loaned by F W B Saunders of Sherborne, Dorset and the Yeovil Motor Company of Yeovil, Somerset. Thanks are also due to Sykes-Pickavant who supplied some of the workshop tools, and all those people at Sparkford who assisted in the production of this Manual.

© Haynes Publishing Group 1987, 1988, 1989 A book in the Haynes Owners Workshop

Manual

Printed by J. H. Haynes & Co. Ltd, Sparkford,

Series

Nr Yeovil,

Somerset BA22 7JJ, England All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 85010 514 6 British Library Cataloguing in Publication Data Brown, Colin. 7942 Volvo 340 and 360 Series Owners Workshop Manual — 2nd Ed. 1. Cars. Maintenance and repair — Amateurs’ manuals |. Title Il. Series 629.28'722 ISBN 1 85010 5146

Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Contents Introductory pages About this manual

Introduction to the Volvo 300 Series General dimensions, capacities and weights Jacking and towing Buying spare parts and vehicle identification numbers General repair procedures Tools and working facilities Conversion factors Safety first! Routine maintenance Recommended lubricants and fluids Fault diagnosis

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Fig. 10.54 Wiring diagram for 1984 B14 models (continued) 7

381

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Fig. 10.54 Wiring diagram for 1984 B14 models (continued)

382

Fig. 10.55 Wiring diagram for 1984 B19A models Use as supplement to Fig. 10.54

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Fig. 10.56 Wiring diagram for 1984 B19E models Use as supplement to Fig. 10.54

é

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384

Key to Figs. 10.57 and 10.59 Location (B14 only)

Location (B14 only)

1.0 2.0 2 22 23 2.4

Battery Central junction box/fuse box Main beam/dipped beam relay (bridge) Start inhibitor relay, AT ‘X'-contact relay

1c 2h 4f 4g 4h 4f

Al A2 A3 Ad A6 A7 A8 AQ A10 B1 B2

Direction indicator light, right Parking light, right

2a 2a

Headlight, right Headlamp wiper motor, right (Nordic)

2a 3a

Headlamp wiper motor, left (Nordic) Horn Headlight, left Parking light, left Direction indicator light, left Direction indicator light, right wing Windscreen washer pump Coolant temperature sensor Carburettor pilot jet (and preheating B200K) Oil pressure sensor Four-way valve, AT Alternator and voltage regulator Distributor Brake fluid level float AT vacuum control unit (including tachometric relay) Hydraulic switch, brake master cylinder, AT Electronic ignition Air temperature sensor Declutching servo, AT

Ta 7b 8a 8a 9a 2d 3d 4d 4d 5e 5g 6b 6c 6e

B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B19 B20 B21 B24 C1 C2 C3

Windscreen wiper motor Direction indicator light, left wing Starter motor Headlamp washer pump Cooling fan (radiator), B14 Switch, cooling fan B14 Engine revs sensor, electronic ignition Direction indicator lamp, right Heated rear window indicator lamp Parking light indicator lamp

6g Te 7g 7c 7d 8g 9d 4c 3d 5a 5b 7f 6i Ti 6i

C5 C6 C7 C8 cg C10 C11 Ci2 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 D22 El

Rear fog lamp indicator lamp

Ti

Main beam indicator lamp Seat belt indicator lamp a Hazard warning indicator lamp

Ti Ti Ti

Brake fluid level indicator lamp Oil pressure indicator lamp Choke indicator lamp (carburettor engines) Handbrake indicator lamp Charge indicator lamp Direction indicator lamp, left Lamps, instrument lighting Fuel reserve indicator lamp (LED) Coolant temperature indicator lamp (LED) Clock, instrument panel Fuel gauge Engine, temperature gauge Rev counter Air temperature gauge Lamp, gearchange indicator (LED) Switch for glove compartment light

Ti 7i Ti 7i Ti Ti

Ti 8i 6i

Lamp, glove compartment Lamp, ashtray

7i 8i 6i Ti 6i 8i 3m 3m 5m

Lamp, cigar lighter

5m

Cigar lighter Radio (optional) Lamp, heater controls lighting Blower switch Ignition switch Windscreen wash/wipe switch Choke switch Horn switch Direction indicator switch Lighting switch Lamp, lighting switch Illuminated switch, heated rear window Illuminated switch, rear foglamp(s) Dimming switch (illuminated) instrument lighting Hazard warning switch (illuminated) Lamp, console clock lighting Console clock (optional) Lamp, ignition switch lighting

5m 5n 5m 5m 6m 6m 7m 7n 7m 8m 8m 9m 9m 8m 5n 5n 6n 6m

Heater blower motor

5g

385

Key to Figs. 10.57 and 10.59 (continued)

E2 E3 E4 E5 E6 E7 E8 EQ E10 E11 E12 F1 F2 F3 F4 F5 F6 F7 F8 FQ F10 F11 F12 F13 F14 F15 G1 G2

Location

Location

(B14 only)

(B14 only)

Blower resistances

5h 6h 6h 7h 9h 5i 6m 6h

Intermittent wiper relay (DL) Kickdown switch, AT Brake light switch Combined direction/hazard flasher unit Relay, blower motor speed 3

Ignition switch relay Intermittent wash/wipe relay (GL, -S, -E, -T) Main lighting relay Rear foglamp relay Delay relay, interior lights (GLE, GLT)

7m

8m 3m im 9m

Interior light switch, right door Interior light switch, left door Interior light, front Switch, central locking system (driver's door) Motor, central locking system, LH rear door Motor, central locking system, RH front door* Motor, central locking system, RH rear door Power window switch, right door Power window. switch, left door Power window motor, left door Power window motor, right door

Sp 8n 80 2n 20 70

70 70 30 in 9n lo 90 30 3n

Interior light switch, RH rear door Interior light switch, LH rear door RH rear interior light LH rear interior light Seat cushion contact, front passenger (AT) Switch and lighting, selector lever panel

G2 G3 G4 G5 G6 G7 G8 G9 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H14 H15 H16 J1 J12

(MT) Reversing light switch Low ‘gear’ hold switch, AT Seat belt contact, front passenger Top gear switch, gear change indicator Handbrake switch

Seat belt contact, driver Seat heating elements and thermostat Declutching servo switch, AT Direction indicator light (rear), right Tail/brake light, right Tail light, right Rear foglamp, right Reversing light, right Number plate light, right Number plate light, left Reversing light, left Rear foglamp, left

Tail light, left Tail/brake light, left Direction indicator light (rear), left Boot light lamp Fuel tank float Heated rear window Boot light switch Electronic control unit, LE-Jetronic Control relay, LE-Jetronic

*RHD cars: Left-hand front door

Colour code BI BI-R BI-Y Br

Blue Blue/red Blue/yellow Brown

L Or P R

Gn-Y Gr

green/yellow Grey

SB SB-BL

Orange Pink

SB-Br Black/brown SB-R_ Black/red WwW White

Red Black Black/blue

W-BI

White/blue

W-Br W-Gn_

White/brown White/green

Lilac

W-R W-SB_ yi

White/red White/black Yellow

3n 4n 5o

8i 50 60

60 4n

386

Fig. 10.57 Wiring diagram for 1985 B14 models

387

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Fig. 10.57 Wiring diagram for 1985 B14 models (continued)

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Fig. 10.57 Wiring diagram for 1985 B14 models (continued)

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Fig. 10.59 Wiring diagram for 1985 B200 models Use as supplement to Fig. 10.57

391 Key to Fig. 10.60 Current track Component 1

Battery

2 2 2 2a

Horn Second horn (360) Horn switch Cooling fan, radiator (340)

2a

Thermostatic switch, cooling fan (340)

3 4 5 6 6 6 7 7 8 8 9 9 9 9 9a 9a 9c 10 10 10a 11 12 12a 12a 13 14 14a 14a 14b 14c 14c 15 15 16 16 L

Radio connection Cigar lighter Clock Brake light switch Tail/brake light, right Tail/brake light, left Boot light lamp Boot light switch Switch for glove compartment light Lamp, glove compartment Interior light switch, right door Interior light switch, left door Interior light fitting Lamp, ignition switch light Switch, central locking system Motors, central locking system Interior light delay relay (B200E) Ignition switch ‘*X’ contact relay Ignition switch relay Starter motor Electronic ignition system Gearchange indicator Switch, gearchange indicator Rev counter (360) Distributor Fuel cut-off relay Throttle butterfly switch Carburettor pilot jet, B14E, B200KE Powered window rocker switches Powered window motors Alternator and voltage regulator Battery charge indicator lamp Choke indicator lamp Choke switch Oil pressure switch

17 18 18 19 19 20 20 20

Oil pressure indicator lamp Brake fluid level float Brake fluid level indicator lamp Handbrake indicator lamp Handbrake switch Fuel reserve indicator lamp Fuel gauge Fuel tank float

21

Air temperature sensor

21 22 Ze 22 23 23 23 ZS 24 25 26 26a 27 28 29 29 30 30 30 31 31a

Air temperature gauge Coolant temperature sensor Coolant temperature indicator lamp Coolant temperature gauge Seat belt indicator lamp Seat cushion contact, front passenger Seat belt contact, front passenger Seat belt contact, driver Headlamp wiper motor, right (Nordic) Screen washer pump Headlamp washer pump (Nordic) Headlamp wiper motor, left (Nordic) Intermittent wash/wipe relay (GL, -S, -E, -T) Intermittent wiper relay (DL) Windscreen wash/wipe switch Windscreen wiper motor Blower switch Heater blower motor Blower resistances Relay, heater blower switch Heated rear window (and door mirrors) indicator lamp

31a 31a 32 32 33 33 33a 33a 33a

Door mirror heater, left Door mirror heater, right Rear window heater switch Heated rear window Carburettor pilot jet, B2Z00KS/KO Carburettor preheating, B200KE Power mirror motor, left Power mirror motor, right Power mirror switch, left

Component number 1.0

A7 A4 D12 B20 B21

D6 D5 C18, (D21) E5 H2 H11 H13 H16 D1 D2

FA F2 F3 D22 F4 F566, 7 E12 D9 2.4 E8 B17 Bi2 C23 G5 C21 B8 B28 B29 B4 F8, F9 FLO Se TT B7 C13 C11 D11 B5 C10 B9 C9 C12 G6 C16 C19 H14 B13 C22 B3 C17 C20 C7 G1 G4 G7 A5 B2 B19 A6 EQ E3 D10 B15 D8 E1 E2 E7 C2

F16 F17 D16 H15 B4 B27 F18 F19 G14

Current track Component 33a 33b 33b 33b 34 34 34 30 35 35a 35a 36 37 37 37

Component number

Power mirror switch, right Rear window wash/wipe switch (GB) Rear window wiper motor (GB) Rear window washer pump (GB) (MT) Reversing lights switch Reversing light, right Reversing light, left Seat heating elements and thermostat, driver Seat heating switch, driver Seat heating elements and thermostat, passenger Seat heater switch, passenger

G15 G16" H17 B30 G2 H5 H8 G8 G12 G11 G13

Combined direction/hazard flasher unit

E6

Direction indicator lamp, left wing

B16

Direction indicator light (rear), left Direction indicator lamp, left

H12 C14

37,

Direction indicator, right

37 Si 37 37 37. 37 37 38 39 39

Direction indicator lamp, right wing Direction indicator light (rear), right Direction indicator lamp, right Direction indicator, left ‘ Switch, direction indicators/flasher Hazard warning switch Hazard warning indicator lamp Vehicle lighting switch Number plate light, left Tail light, left

39 39 39

Tail/brake light, left Tail/brake light, right Tail light, right

39

Number plate light, right

40 40 40 40 40 40 40 40

Parking light indicator lamp Parking light, left Lamp, ashtray lighting Lamp, cigar lighter Lamp, heater controls lighting Lamp, vehicle lighting switch Lamps, illumination switches Lamp, (console) clock lighting

Al B1 H1 Le] A10 D13 D19 C8 D14 H7 H10 H11 H2 H3 H6

C3 AQ D3 D4 D7 D15 D16, D17, D18, D19 D20

40

Lamps, instrument lighting

40 40a 41 41a 41a 41a 42 42

Dimmer rheostat, instrument lighting Resistor, instrument lighting (340 basic) Parking light, right Main vehicle lighting relay Rear foglamp relay Ignition switch Fuse, rear foglamps (not CH) Rear foglamp switch

42 42

Rear foglamp indicator lamp Rear foglamp, right

42 42 42 43 43 43 43 43 43

Rear foglamp, left Headlamp, left, dipped beam Headlamp, right, dipped beam Main beam/dipped beam relay Headlamp, left, main beam Headlamp, right, main beam Main beam indicator lamp Main beam switch Main beam indicator lamp

H9 A8 A3 Pas A8 A3 C6 D13 C6

43

Main beam flash switch

D13

45 46 46 47 48 49 50 51 52

Control relay, LE-Jetronic Fuel pump, LE-Jetronic Fuse, fuel pump, LE-Jetronic Kickdown switch Low “gear” hold switch, AT Low “gear” hold indicating lamp, AT Hydraulic switch, brake master cyl., AT 4-Way valve, AT AT vacuum control unit (including tachmetric relay) Declutching servo switch, AT Declutching servo, AT AT selector level panel switch and lamp Start inhibitor relay, AT Fuse, foglamps GLT, 360 GLE Foglamp GLT, 360 GLE, left Foglamp power relay GLT, 360 GLE Foglamp switch GLT, 360 GLE Foglamp control relay GLT, 360 GLE (not Germany and Austria) Foglamp GLT, 360 GLE, right

J12 J14 w13 E4 G3 G3 B11 B6

44

53 54 55 56 57 57 58 58 58

58

Electronic control unit, LE-Jetronic

=

C15 D18 D23 A2 E10 E11 Dg E13 D17 G5 H4

J1

B10 G9 B14 G2

23 B31

All B32 G10 E14 A12

392

10a

9a

10

11

Colour code

12 (38) 13 14 tha

14D

w-

(B14 ,B200KE)

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(W-SB) Fig. 10.60 Schematic diagram for all 300 Series models, 1986 on

BI BI-R BI-Y

Blue Blue/red Blue/yellow

Br Gn Gn-Y

Brown Green Green/Yellow

Gr L Or P R SB SB-BI SB-Br SB-R Ww W-BI W-Br W-Gn_ W-R W-SB Y

Grey Lilac Orange Pink Red Black Black/blue Black/brown Black/red White White/blue White/brown White/green White/red White/black Yellow

393

15

Bl (B200)

16 17 18 19

87

x-contact [

30

30

oO

N Se) So

(2.4)

N

Zi

28

29

Fig. 10.60 Schematic diagram for all 300 Series models, 1986 on (continued)

394

30

31

31a

32

33

30

33b

34 BS

35a

36 37

Fig. 10.60 Schematic diagram for all 300 Series models, 1986 on (continued)

395

38

37

40

ONLY, (SWEDEN

40a

41

41a

42

43

0136/1

Fig. 10.60 Schematic diagram for all 300 Series models, 1986 on (continued)

396 (10A)

SB(B14S,MT,AT)

(12)

87

5

Jx-contact

47

(2.4)

52

53

55

10

11

Fig. 10.61 Supplementary diagram for 1986 on B14 models with automatic transmission

eae a

Aut

(11)

44

a

46

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a

O

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2

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30

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58

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Fig. 10.62 Supplementary diagram for 1986 on B200E models

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30

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12

45

Index A About this manual - 5 Accelerator cable removal and refitting — 124 linkage adjustment — 125 pedal removal and refitting — 122 Alternator dismantling, servicing and reassembly — 313 maintenance and special precautions — 312 removal and refitting — 312 Ancillary components installation — 52 refitting — 68 removal from engine — 40, 54, 71 Angular position sensor (Renix ignition) — 173 Air filter and housing removal and refitting — 111 to 114 thermostatic valve — 115 Automatic transmission description — 190 drivebelts removal, refitting and adjustment — 192 driveshaft removal, inspection and refitting — 201 fault diagnosis — 206 primary and secondary units removal and refitting as one assembly — 194 primary unit overhaul — 194 removal and refitting — 193 propeller shaft removal and refitting — 202 routine maintenance — 192 secondary unit overhaul — 198 removal and refitting — 193 selector lever removal and refitting — 202 to 206 specifications — 188 torque wrench settings — 190 vacuum control microswitch adjustment — 206

Battery charging — 311 electrolyte replenishment — 311 specific gravities —- 311 maintenance — 311 removal and refitting - 310 Bleeding the brakes - 246 Bodywork and fittings -— 273 et seq Bodywork and fittings bonnet and lock — 290 boot lid (saloon) — 298 bumpers — 292 central door locking system — 289

description —- 273 doors — 276, 283 door locks and handles — 285 electric window motor and mechanism — 288 facia panel — 292

front grille — 292 front door mirrors - 298 front door window - 281 front door quarterlight — 283 front wings and front panel — 276 heating system — 301 heater — 301 to 304 heater control cables — 305 heater control panel — 304 heater matrix — 304 maintenance bodywork and underframe — 274 carpets and upholstery — 275

hinges and locks — 276 plastic components — 276 rear ashtray — 298 rear door window and quarterlight — 283

Index recirculation vacuum control valve — 306 repair sequence (colour) — 278, 279 seat belts — 307 seats — 307 spoilers — 307 sunroof — 298 sunroof handle — 301 tailgate — 287 tailgate lock — 290 transmission tunnel console — 296 trim panels — 280, 283 rear window — 281 side windows — 281 window channel — 283 window motor and mechanism — 288 window winder mechanism — 286 windscreen glass — 277 windscreen header panel — 280 Bonnet removal and refitting — 290 Bonnet lock removal and refitting — 290 Boot lid (saloon) removal and refitting — 298 Brake drum

inspection and renovation £ 242 Brake light switch removal, refitting and adjustment — 338 Braking system — 233 et seq Braking system

bleeding — 246 brake disc — 240 brake drum — 242

brake light switch — 338 brake lines (flexible and rigid) — 245 brake shoes — 235 description — 234 disc calipers — 238 disc pads — 234 fault diagnosis — 251 flexible hoses — 245 handbrake — 247 handbrake cables — 247 handbrake lever — 248 hydraulic system — 246 master cylinder — 242 pressure reducing valve — 244 rear brake shoes — 235

routine maintenance — 234 specifications — 233 torque wrench settings — 234 vacuum servo unit — 248, 249

wheel cylinder — 241 Bosch LE-Jetronic fuel injection system description — 145 complete check — 147

idle speed adjustment — 147 safety precautions — 147 Bulb renewal front direction indicator lamps — 324

front fog lamps — 325 front parking lamps — 324 headlamps — 324 interior lamps — 325 rear lamp cluster — 325 rear number plate light — 325 side repeater lamps — 325 Bumpers removal and refitting — 292 Buying spare parts — 9

Cc Camshaft and followers examination and renovation — 48, 61

399 installation — 50, 88 removal — 43, 74

Capacities (fluids) — 6 Carburettor Solex 32-SEIA REN description — 126 dismantling and reassembly — 134 idling adjustment — 134 removal and refitting — 133 Solex 34-34 CISAC description — 140 dismantling and reassembly — idle speed and CO adjustment removal and refitting — 141 Solex 28-34 CISAC description — 142 dismantling and reassembly — idle speed and CO adjustment removal and refitting — 142

141 — 140

144 — 142

Weber 32 DIR description — 126 dismantling and reassembly — 131 idling adjustment — 129 removal and refitting — 130

Zenith 175 CD-2SE description — 136 dismantling and reassembly — 138 idling adjustment — 136 removal and refitting — 138 specifications — 107 to 110 torque wrench settings — 110 Carpets - 275 Central door locking system — 289 Change-up indicator system — 339 Chassis number - 9 Choke cable removal and refitting — 125 Clutch — 175 et seq

Clutch automatic transmission models — 176 declutching servo removal, refitting and adjustment — 179 description — 176

removal and refitting — 177 shaft and bearing removal and refitting — 178 thrust bearing removal and refitting — 178 manual transmission models — 180 adjustment — 180 cable renewal — 180 description — 180 pedal removal and refitting — 182 removal and refitting — 182 to 186 routine maintenance — 180 shaft and bearing removal and refitting — 186 thrust bearing removal and refitting — 186 fault diagnosis — 187 specifications — 175 torque wrench settings — 175

Coil - 164

Connecting rods examination and renovation — 47, 83 installation — 50, 85 removal — 43, 78

Conversion factors — 13 Compression test — 93 Condenser testing, removal and refitting — 162 Contact breaker points adjustment and lubrication — 159 renovation and renewal — 160 Coolant capacities — 94 mixture renewal — 98 pump removal and refitting — 100

400

a

Cooling fan — 104 extra fan for towing — 106 viscous coupling type — 105 Cooling system — 94 et seq Cooling system description — 95 draining and flushing — 96 drivebelt removal and adjustment — 103 electric cooling fan and switch — 104 fault diagnosis — 106 filling — 97 pump removal and refitting — 100 radiator — 98 specifications — 94 thermal time switch — 104 thermostat — 99 torque wrench settings — 95 water temperature sender — 104

Crankcase examination and renovation — 47 Crankcase ventilation system description and maintenance — 45, 81 Crankshaft bearings examination and renovation — 60, 82 examination and renovation — 47, 60, 82 front oil seal removal and refitting — 79 front plate refitting — 86 removal — 76 installation — 49 intermediate shaft gears refitting — 66 rear oil seal removal and refitting — 78 renewal — 45 rear pilot bearing removal and refitting — 79 refitting — 61, 66 removal — 45, 78 Cylinder block and crankcase ancillary reassembly checks — 87 examination and renovation — 82 Cylinder head decarbonising — 49, 61 dismantling — 41, 56, 74 reassembly and installation — 51, 65, 87 refitting — 65, 89 removal — 40, 74 renovation — 49 Cylinder bores examination and renovation — 61 Cylinder liners examination and renovation — 47 installation — 50 removal — 43

D Damage repair major — 276 minor — 275 De Dion axle removal and refitting — 263 Decarbonising — 48 Dimensions (general) — 6 Direction

indicator/hazard

flasher system — 329

Disc (brake) caliper removal, servicing and refitting — 238 examination, removal and refitting — 240 pads inspection and renewal — 234 specifications — 233 Distributor dismantling and reassembly — 162 overhaul (electronic ignition) — 168 removal and refitting — 162, 168, 172 specifications — 157, 158

Index Door

lock removal and refitting — 285 lock cylinder removal and refitting — 286 mirrors — 298 outside handle removal and refitting — 285 rattles rectification — 276 removal and refitting — 283

trim panel removal and refitting — 283 Drivebelt removal and adjustment — 103 —

E Electrical faults — 25 Electrical system — 308 et seq Electrical system alternator — 312 to 317 battery — 308, 310, 311 brake light switch — 338 bulb wattages — 309 change-up indicator system — 339 description — 310 direction indicator/hazard flasher system — 329 door speakers — 340 facia panel switches — 330 fault diagnosis — 346, 347 foglamps — 328 fuses and relays — 309, 310 headlamps — 326 headlamp wipers — 335 horn — 337 horn control — 338 ignition/steering lock switch — 329 instrument panel — 331

lighting system — 324 radio equipment installation — 340 to 346 rear lamp cluster — 329 rear screen wiper — 336 reversing light switch — 338 routine maintenance — 310 seat belt warning system — 338 seat heating pads — 338 specifications — 308 speedometer cable — 330 standard fit radio/tape player — 339 steering column stalk switches — 329 temperature and fuel gauges — 332 window switches — 339 windscreen washer — 336 windscreen wiper blades — 332 linkage — 333 motor — 334

wiring diagrams — 348 to 397 Electric window motor and mechanism removal and refitting — 288 Electric window switches removal and refitting — 339 Electronic control unit removal and refitting — 150 Engine — 29 et seq Engine (general and B14 type) adjustment after overhaul — 53 ancillary components removal — 40

camshaft and followers — 43 crankcase ventilation system — 46 crankshaft and main bearings — 45 crankshaft rear oil seal — 45 cylinder head — 40 cylinder liners — 43 description — 36 dismantling — 40 examination and renovation (general) — 46 fault diagnosis — 93 flywheel — 45

401

Index LL

installation — 52 number — 9 oil pump and filter — 41 operations possible with engine in car — 38 operations requiring removal of the engine — 38 pistons and connecting rods — 43 reassembly — 49 removal — 39 routine maintenance — 36 specifications — 30 sump — 41

timing cover, gears and chain — 42 torque wrench settings — 31 Engine (B19 and B200 types) adjustment after major overhaul — 69 description — 53 dismantling — 54 operations possible with engine in car — 53 Operations requiring removal of engine — 54 reassembly — 61 refitting — 69 removal — 54 routine maintenance — 53 specifications — 31, 32, 33, 34 torque wrench settings — 33, 34 Engine (B172 type) ancillary components — 71 camshaft — 74 crankshaft — 76 crankshaft oil seals — 78, 79 crankshaft rear pilot bearing — 79 crankshaft ventilation system — 81 cylinder block and crankcase — 82 cylinder head — 74

description — 69 dismantling — 71 engine mountings — 80 examination and renovation — 82 flywheel — 78 intermediate shaft — 81 main bearings — 78 oil pump — 76 oil renewal — 91 oil filter — 91 operations possible with engine in car — 70 operations requiring removal of engine — 70 pistons and connecting rods — 78 reassembly — 84 refitting — 90 removal — 70 routine maintenance — 69 specifications — 34 sump — 75 tappets — 74 timing belt — 73 torque wrench settings — 36 Exhaust manifold removal and refitting — 150 Exhaust system

removal and refitting — 152

>

suspension and steering — 272 Flywheel examination and renovation — 48, 61 installation — 50 removal — 45, 78 Foglamps — 328 Front anti-roll bar removal and refitting — 257 Front coil spring removal and refitting — 255 Front grille removal and refitting — 292 Front hub bearings and seal removal and refitting — 260 Front lower suspension arm removal and refitting — 256 Front radius arm removal and refitting — 257 Front shock absorber removal, servicing and refitting — 256 Front wings and front panel removal and refitting — 276 Fuel and exhaust systems — 107 et seq Fuel and exhaust systems accelerator pedal — 122 air filter and housing — 111 Bosch LE-Jetronic injection system complete check — 147 description — 145 electronic control unit — 150 fuel filter — 150 fuel pump — 150 idle speed adjustment — 147 safety precautions — 147 fault diagnosis — 155, 156 fuel filter (injection models) — 150 fuel pump (injection models) — 150 routine maintenance — 111 specifications — 107 torque wrench settings — 110 Fuel gauges testing, removal and refitting — 332 Fuel pump (carburettor engine) refitting — 68 removal, refitting and overhaul — 116 Fuel pump (fuel injection models) removal and refitting — 150 Fuel tank removal and refitting — 118 to 121 transmitter unit removal and refitting — 122 Fuses and relays — 322 ratings and circuits — 309, 310

G General dimensions, capacities and weights — 6 General repair procedures — 10 Gudgeon pins examination and renovation — 60

F

H

Facia panel removal and refitting — 292 to 296 Facia panel switches removal and refitting — 330 Fault diagnosis automatic transmission — 206 braking system — 251 clutch — 187 engine — 93 fuel and exhaust systems — 155 general — 25 ignition system — 166, 169, 173 transmission and final drive — 206, 232

Handbrake adjustment — 247 Handbrake cable removal and refitting — 247 Handbrake lever removal and refitting — 248 Headlamp alignment — 328 Headlamps, front indicator lamps and front foglamps removal and refitting — 326 Heater control cables fitting and adjustment — 305 control panel removal and refitting — 304 matrix removal and refitting — 304 removal and refitting — 301 to 304

402

a

ane

NN

DeSean

Heating system — 301

Horn description, removal and refitting — 337 Horn control removal and refitting — 338 HT leads -— 165 Hydraulic brake lines (flexible and rigid) inspection, removal and refitting — 245 Hydraulic system bleeding - 246

O Ignition system — 157 et seq Ignition system conventional system — 159 description — 159 contact breaker — 159 fault diagnosis — 166

fault finding — 166 ignition/steering lock switch — 329 routine maintenance — 159 electronic (breakerless) system coil, spark and HT leads — 169

description — 168 distributor — 168 fault diagnosis — 169 routine maintenance — 168 servicing and overhaul — 168 timing — 168 electronic (Renix) system angular position sensor — 173 control unit —- 172 description — 170 distributor — 172 fault finding — 173 precautions — 172 routine maintenance — 172 timing — 172 specifications — 157, 158 steering lock switch removal and refitting — 329 timing — 157, 162 torque wrench settings — 158 Inlet manifold removal and refitting — 150 Instrument panel

removal and refitting — 331 Interior trim panels (A, B, C) removal and refitting — 280

Intermediate shaft (engine) examination and renovation — 61 refitting — 66 removal — 81 Introduction to the Volvo 300 Series — 5

J

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DOE Pe

Index

NL tese

Se

M Main bearings examination and renovation — 47 installation — 49 removal — 45, 78 Maintenance bodywork and underframe — 274 carpets — 275 hinges and locks — 276 upholstery — 275 Manifolds removal and refitting — 150 Manual transmission description — 208 driveshaft removal, inspection and refitting — 221 fault diagnosis — 232 five-speed gearbox description — 225 overhaul — 227 to 229 final drive flange and oil seal removal and refitting — 229 final drive pinion shaft oil seals renewal — 232 final drive rear cover gasket renewal — 232 final drive unit removal and refitting — 229 four-speed gearbox overhaul — 212 to 218 gearbox (B14 and B172) removal and refitting — 210 gearbox and fina! drive removal and refitting — 211 (B14 and B172) - 211 (B19 and B200) — 219 gearbox cover gasket (B19 and B200) renewal — 220 gearbox front casing (B19 and B200) removal and refitting — 220 gear selector rod removal and refitting (B14 and B172) — 221 (B19 and B200) — 223 propeller shaft (B14 and B172) removal and refitting — 218 routine maintenance (gearbox) — 208 specifications — 189 torque tube (B19 and B200) removal and refitting — 220 torque wrench settings — 190 transmission mountings removal and refitting — 225 Master cylinder removal, servicing and refitting — 242 Mirrors (front door) removal and refitting — 298

O Oil filter refitting — 68, 91

L

removal — 41, 91 Oil pump examination and renovation — 45, 59, 76 installation — 51 removal — 41, 76 Operations possible with engine in car — 70 Operations requiring engine removal — 70

Liners (cylinder) installation — 50 removal — 43

P

Jacking and towing - 8

Lighting system bulb renewal — 324 direction indicator/hazard flasher — 329 front indicator lamps — 326 front fog lamps — 326 headlamps — 326 rear lamp cluster — 329 Lubricants and fluids (recommended) — 24

Pedal (accelerator) removal and refitting — 122

(clutch) removal and refitting — 182 Pistons examination and renovation — 60, 83 installation — 50, 85 removal — 43, 78

ee

Piston rings examination and renovation — 60 Pressure reducing valve description, removal and refitting — 244

R Radiator removal, inspection, cleaning and refitting — 98 Radio equipment (mobile) interference-free installation aerials — 340 component terminal markings — 343 connectors — 345 citizens’ band radio — 345 interference — 342

Index removal and refitting — 318 testing in car — 317

Steering angles and front wheel alignment — 252, 271 Steering column removal, servicing and refitting — 266 stalk switch removal and refitting — 329 Steering gear overhaul — 267 to 270 removal and refitting — 266 Steering shaft vibration damper removal and refitting — 266

Steering swivel balljoint removal and refitting — 256

Steering wheel removal and refitting — 265 Sump installation — 51

loudspeakers — 341

other vehicle radio transmitters — 346 radio/cassette breakthrough — 345 suppression methods — 343 unit installation — 341 Radio/tape player (standard fit) door speakers removal and refitting — 340 removal and refitting — 339 Radius arm removal and refitting front — 257 rear — 263 Rear ashtray removal and refitting — 298 Rear hub bearings and seal removal and refitting — 264 Rear lamp cluster removal and refitting — 329 Rear screen wiper blade and motor removal and refitting — 336 Rear shock absorber removal and refitting — 263 Rear spring removal and refitting — 262 Rear spring bushes removal and refitting — 263 Recirculation vacuum control valve removal and refitting — 306 Recommended lubricants and fluids — 24 Renix ignition system — 170 Repair damage major — 276 minor — 275 Repair procedures (general) — 10 Reversing light switch removal, refitting and adjustment — 338 Routine engine maintenance — 36, 69 Routine maintenance (general) — 15

removal — 41

engine in car — 76 engine out of car — 75 Sunroof removal, refitting and adjustment — 298 Sunroof handle removal and refitting — 301 Suppression methods (radio) generators — 344

ignition — 343 other equipment — 344 voltage regulators — 344

Suspension and steering — 252 et seq Suspension and steering De Dion axle — 263 description — 253 fault diagnosis — 272 front anti-roll bar — 257 front coil spring — 255 front hub bearings and seal — 260 front lower suspension arm — 256 front radius arm — 257 front shock absorber — 256 front wheel alignment — 271 ignition/steering lock — 266 rear hub bearings and seal — 264 rear radius arm — 263 rear shock absorber — 263 rear spring — 262 rear spring bushes — 263 routine maintenance — 253 specifications — 252 steering angles — 271 steering column — 266 steering gear — 266 to 270 steering shaft vibration damper — 266 steering swivel balljoint — 256 steering wheel — 265 torque wrench settings — 253 track rod end balljoints — 270 wheel alignment — 271 wheels and tyres — 271

S Safety first! — 14 Seat belts removal and refitting — 307 warning system — 338 Seat heating pads — 338 Seats removal and refitting — 307 Spare parts buying - 9 Spares and tool kit — 26 Spark plugs — 158, 165 Speedometer cable removal and refitting — 330 Spoiler (rear) removal and refitting — 307

Starter motor description — 317 overhaul — 318

es

T Tailgate removal and refitting Tailgate lock removal and refitting Temperature and fuel testing, removal and Thermal time switch removal and refitting Thermostat removal, testing and Timing belt examination — 73 removal and refitting

— 287 — 290 gauges refitting — 332

— 104

refitting — 99

— 66, 73, 89

403

eee

404 Timing cover, gear and chain installation — 51 removal — 42 Timing gear and chain examination and renovation — 48 Timing (ignition) adjustment — 162 Tools and working facilities — 11 buying tools — 12 care and maintenance of tools — 12 introduction — 11 spanner jaw gap comparison table — 12 special tools — 11 tool kits maintenance and minor repair — 11 repair and overhaul — 11 working facilities — 12 Towing - 8 Transmission and final drive — 188 et seq Transmission and final drive automatic transmission — 190 to 206 manual transmission — 208 to 232 specifications — 188 to 190 torque wrench settings — 189, 190 Transmission tunnel console

removal and refitting — 296 Tyre pressures — 253 Tyre sizes — 253

U Upholstery maintenance — 275

Vv Vacuum servo unit air filter renewal — 250 » description — 248 non-return valve renewal — 250 testing, removal and refitting — 249 Valve clearances adjustment — 52, 67, 90 Valve grinding — 48, 61

Index Vehicle identification numbers — 9 Ventilation system — 306 Viscous coupling cooling fan removal and refitting — 105 Voltage regulator — 322

Ww Water pump removal and refitting — 100 Weights (general) — 6 Wheel cylinder removal, servicing and refitting — 241 Wheel specifications — 253 Wheels and tyres care and maintenance — 271 Window channel removal and refitting — 283 Window motor and mechanism removal and refitting — 288 Windows removal and refitting

front door — 281 front door quarterlight — 283 rear door and quarterlight — 283 rear (hatchback and saloon) — 281 side (fixed) — 281 side (hinged) — 281 Window winder mechanism removal and refitting — 286

Windscreen glass removal and refitting — 277 Windscreen header panel removal and refitting — 280 Windscreen washer system maintenance — 336 Windscreen wiper blades removal — 332 linkage removal and refitting — 333

motor overhaul — 334 removal and refitting — 333 Wiring diagrams — 348 to 397

Models covered by this manual All Volvo 340, 343 & 345 models; 1397 cc & 1721 cc All Volvo 360 models; 1986 cc Does not cover.LPG conversion

The clear, step-by-step illustrated instructions cover the dismantling, inspection, repair and refitting of the engine, cooling system, fuel and -emission control systems, exhaust, ignition system, clutch, manual gearbox, propeller shaft or drive shafts, braking system, electrical system, suspension, steering, bodywork and fittings. Routine maintenance, complete specifications and detailed fault diagnosis procedures are also included. For rear axle differential units and automatic transmissions (where applicable) the removal, refitting and fault diagnosis procedures only are covered. ONLY HAYNES COMPLETELY STRIP AND REBUILD THE CAR FOR EACH MANUAL

‘These are really worthwhile manuals which can save you a lot of money.” Autocar

‘Haynes manuals are outstanding for giving the learner mechanic an easy to follow guide to doing most any type of repair on maintenance work on his or her car.’ Road & Track ‘These authentic manuals are actually written from practical experience ...’ Car Mechanics

Whether you just want to change your oil or replace your plugs, or change your clutch or rebuild your gearbox, the Haynes manual will show you how, and can help you save pounds on servicing and repair bills.

A Haynes manual can help you stretch your motoring budget that little bit further in other ways too. Regular maintenance and servicing will mean your Car is safer to drive whilst giving you more of those precious mpg.

What’s more, a car that is well looked after will hold its price better and last a lot longer!

H 923714

Wil

ISBN 1 85010 514 6

SNA Se EXPLAIN BEST GO BY THE BOOK

‘Excellent value for money, beginners and experts should find it equally useful, overall a mine of information.’ Motor

‘It is thus opportune that a simply splendid Owners Workshop Manual has just come out. Every imaginable job is illustrated ...’ Autosport ‘For the home .mechanic Haynes DIY workshop manuals show clearly step-by-step service Operations in pictures.’ Sunday Mirror